Article of footwear

ABSTRACT

An article of footwear having an upper constructed at least in part from a sock-like structure having at least two or more layers in a portion of, or in all of, its regions. The sock-like structure may be knitted and may be a unitary construction such that one portion folds over another portion. Separately formed attachments may include parts of the sole, liners, decorative elements, cording, and structural supports which may be located between the layers of the sock-like structure. The attachments may be molded and conformed into shape directly on to the sock-like structure.

FIELD OF THE INVENTION

The present invention pertains to an article of footwear, and more particularly to an article of footwear having an upper comprised at least in part of a multi-layer sock-like structure.

BRIEF SUMMARY OF THE INVENTION

This invention relates to an article of footwear having an upper constructed at least in part from a sock-like structure. The sock-like structure has at least two or more layers in a portion of, or in all of, its regions. The sock-like structure may be knitted and may be of a unitary construction such that one portion folds over another portion. Material may include synthetic textiles and/or natural fiber materials. The materials may also contain hot melt material which may be melted or remain un-melted. External components with a variety of characteristics or structures may be added to the sock-like structure to enhance the function, comfort, and/or ornamentation of the article of footwear. External components may include parts of the sole, liners, and structural supports. A portion of such components may be located between the layers of the sock-like structure. The process of manufacture may include the use of lasts for molding and heating purposes, as well as the use of a 3-dimensional printing process that may further involve the use of a robotic conforming process.

BRIEF DESCRIPTION OF DRAWINGS

These and other features of this invention will be best understood by reference to the following detail description of a preferred embodiment of the invention, taken in conjunction with the accompanying drawings in which:

FIG. 1A is a photograph of an unfolded configuration of an exemplary embodiment of the knitted textile element used in an upper.

FIG. 1B is a photograph of a folded configuration of the knitted textile element of FIG. 1B.

FIG. 2A is an unfolded configuration of an exemplary embodiment of the knitted textile element in an upper.

FIG. 2B is a folded configuration of the knitted textile element of FIG. 2A

FIG. 2C is a folded configuration of the knitted textile element of FIG. 2B with a closed toe end.

FIG. 3A is an unfolded configuration of the knitted textile element in an upper.

FIG. 3B is a folded configuration of an exemplary embodiment of the knitted textile element of FIG. 3A

FIG. 3C is a folded configuration of the knitted textile element of FIG. 3B with a closed toe end.

FIG. 4A is an unfolded configuration of an exemplary embodiment of the knitted textile element in an upper.

FIG. 4B is a folded configuration of the knitted textile element of FIG. 4A

FIG. 4C is a folded configuration of the knitted textile element FIG. 4B with a closed toe end.

FIG. 5A is an unfolded configuration of an exemplary embodiment of the knitted textile element in an upper.

FIG. 5B is a folded configuration of the knitted textile element of FIG. 5A

FIG. 5C is a folded configuration of the knitted textile element of FIG. 4B with an inserted insole/midsole.

FIG. 5D is a folded configuration of the knitted textile element of FIG, 4C and a closed aperture.

FIG. 6A is an unfolded configuration of an exemplary embodiment of the knitted textile element in an upper.

FIG. 6B is a folded configuration of the knitted textile element of FIG. 6A.

FIG. 6C is a folded configuration of the knitted textile element of FIG. 6B with a closed toe end.

FIG. 7 is a Cross section view of the exemplary embodiment of the knitted textile.

FIG. 8A is an unfolded configuration of an exemplary embodiment of the knitted textile element in an upper.

FIG. 8B is a folded configuration of the knitted textile element of FIG. 8A

FIG. 8C is a folded configuration of the knitted textile element of FIG. 8B with a closed toe end.

FIG. 9 is a photograph of an exemplary embodiment of an upper.

FIG. 10A is an unfolded configuration of an exemplary embodiment of the knitted textile element in an upper.

FIG. 10B is a folded configuration of the knitted textile element of FIG. 10A

FIG. 10C is a folded configuration of the knitted textile element of FIG. 10B with a closed toe end.

FIG. 11A is an unfolded configuration of an exemplary embodiment of the knitted textile element in an upper.

FIG. 11B is a folded configuration of the knitted textile element of FIG. 11A,

FIG. 11C is a folded configuration of the knitted textile element of FIG. 11B with a closed toe end.

FIG. 12A is an unfolded configuration of an exemplary embodiment of the knitted textile element in an upper.

FIG. 12B is a folded configuration of the knitted textile element of FIG. 12A

FIG. 12C is a folded configuration of the knitted textile element of FIG. 12B with a closed toe end.

FIG. 13A is an unfolded configuration of an exemplary embodiment of the knitted textile element in an upper.

FIG. 13B is a folded configuration of the knitted textile element of FIG. 13A

FIG. 13C is a folded configuration of the knitted textile element of FIG. 13B with a closed toe end.

FIG. 14A is an unfolded configuration of an exemplary embodiment of the knitted textile element in an upper.

FIG. 14B is a folded configuration of the knitted textile element of FIG. 14A

FIG. 14C is a folded configuration of the knitted textile element of FIG. 14B with a closed toe end.

FIG. 15A is an unfolded configuration of an exemplary embodiment of the knitted textile element in an upper.

FIG. 15B is a folded configuration of the knitted textile element of FIG. 15A

FIG. 15C is a folded configuration of the knitted textile element of FIG. 15B and a separately constructed collar.

FIG. 15D is a folded configuration of the knitted textile element and the separately constructed collar of FIG. 15C attached to each other.

FIG. 16 is a cross-section view of an exemplary embodiment of a knitted textile element of an upper.

FIG. 17A is a photograph of a top view of a shoe.

FIG. 17B is a side view of cross-sectional diagram of an exemplary embodiment of a knitted textile element of an upper.

DETAILED DESCRIPTION OF THE INVENTION

By way of example only, selected embodiments and aspects of the present invention are described below. Each description refers to a figure (“FIG.”) which shows the described matter, Some figures shown in drawings that accompany this specification may depict footwear for either the left or right foot. It should be understood that these figures are merely exemplary and that the invention extends to footwear for both the right and left foot. Each figure includes one or more identifiers for one or more part(s) or elements(s) of the invention.

The invention will now be described regarding an embodiment shown in FIG. 1A and FIG. 1B, which shows a preferred embodiment of the invention's sock-like structure 4 in the unfolded and folded configuration respectively. The sock-like structure 4 in the folded configuration may then be used as at least a portion of an upper 2 for a shoe. The upper may be attached directly or indirectly to a sole.

The sock-like structure may be a unitary knitted tubular textile or knitted in components and attached thereafter. The unfolded configuration shows the sock-like structure to have a first portion 6 and a second portion 8 that are not overlapping. Each portion has a toe region 10 and 12, a midfoot region 14 and 16, a heel region 18 and 20, and a junction portion 22. The two portions may be connected at a junction which may form the collar region or some other region such as the toe region. The sock-like structure may initially have open ends 26 prior to placing the structure in the folded configuration or have a closed end 24 on one of the ends such as the first portion.

In the folded configuration, the first portion may be inverted and folded into the second portion to form a double layered structure. In a preferred embodiment, the fold may be at the location of the junction or collar that creates the opening for receiving a foot. The first portion may also be directly aligned with the second portion such that the respective corresponding collar, heel, midfoot, and toe regions are aligned. The first and/or second toe regions may be knitted with open ends. The open ends of the portions may be closed by stitching, melting, or an other methods known to those with ordinary skill in art. In an alternate embodiment, the collar portion may also be formed by the open ends of the structure and the fold may form the toe portion. In such an embodiment, the fold of the toe portion may then be closed to form the toe end of the upper, and the two layers of the collar portion may be closed to enclose the two layers and anchor the collar portion ends.

The two portions may each have an interior surface 28 and 32 and an exterior surface 30 and 34. The interior surface of the two portions may be located adjacent to each other or separated from each other. The interior surfaces may be fully or partially separated by the insertion of materials between the two portions. The interior surfaces may also be directly attached to each other after the sock-like structure is in its folded configuration. The interior surfaces may be fully or partially attached to each other. Portions of the interior surfaces may freely move with respect to each other at some areas while other areas may be anchored or fixed to each other.

With regard to FIGS. 2a-c , the exterior surface 34 of the second portion is located on the outer layer of the footwear FIG. 2a shows the unfolded configuration of the upper. FIGS. 2b and 2c shows the folded configuration of the upper where the first portion 6 is inside the second portion 8, and the open end 26 of the second portion is later closed to form the toe region 12 of the upper. The exterior surface 30 of the first portion is located on the inner layer of the footwear and may line the void 36 within the structure for receiving a foot. While any material may be used to form the two portions of the structure, the exterior surface of the first portion may be formed of materials that may have a lower coefficient of friction or may be less abrasive to the foot. The exterior surface of the second portion may include more durable and/or dense materials.

The sock-like structure may be constructed of a knitted textile. In a preferred embodiment, the knitted textile may be circular knitted. The textile may, also be flat knitted. The knit may be of a weft or warp configuration. Warp knitting categories include tricot, raschel, and double needle-bar raschel. The knitted textile may also include different knits such as jersey, ribbed, and terry knits. The knitted fibers may include any composition of fibers such as natural fibers, monofilament fibers, wool, cotton, polymers, elastane (Spandex or Lycra), gore, and rayon. The fibers may vary in denier, fineness, spinning count, and linear density. The fibers may be multifilament or monofilaments. The knitted textile may also contain the us of thermoplastic yarn such as fibers made from low temperature nylon hot melt material.

The amount and location of hot melt yarn may be controlled through the design of the knit. The hot melt yarns may be heated and fused or left unfused. A fused area may reduce the movement, stretchability or flexibility to that area. If the concentration of fused yarns is higher, the yarn may be further melted to the extent that the fused can be molded into an entirely different shape. In on embodiment, the knitted hot melt yarns may then be almost completely melted, and then molded into a hardened shell void of substantially all of its knitted construction.

In art exemplary embodiment, the knit containing hot melt yarn is completed the sock-like structure may be closed and placed on a last. Heat and steam may then be applied to activate the hot to melt yarn to fix the shape to the last. Various degrees of heat or steam may be applied to the hot melt yarn in controlling the level of rigidity.

Stretchability of the textile may also be controlled through hot melt yarn content or the amount of elastic yarns integrated into the knit structure. Stretchability may also be designed through the type of knitting or knit design. Stretchability may be a two-way or four-way stretch. Stretchable regions of the upper may include, but are not limited to the toe box, the vamp, the collar, and the ankle region.

Different areas of the invention may contain various types of knits and fibers. In one embodiment, the second portion (i.e. outer layer) may have larger gauge yarn than the first portion (i.e. inner layer). Certain areas may also have varying degrees of elasticity such as the exemplary embodiment shown in FIGS. 3a-c which shows the unfolded and fold configurations of the upper. In this preferred embodiment, areas corresponding to the midfoot arch of the foot max have an elastic region 38 which comprises material exhibiting elastic properties or less stretch resistance. Other areas having elastic material may include the collar, ankle, or vamp region. Other areas may be composed of more rigid materials to provide additional structural support.

In a preferred embodiment, the sock-like structure may be knitted by a circular knitting machine such as a Santoni Knitting Machine, made in Italy, The sock-like structure may be knitted as a unitary piece or combined from separately knitted textiles. The sock-like structure may be knitted with a tubular configuration and open ends on both the first and second portions. The open ends may be stitched to form the closed toe region of the second portion. In an alternate embodiment, the open ends may form the collar portion and the folded end is closed to form the toe. Yet another alternate embodiment may have partial overlapping portions that fold over to form double layers in certain areas, but single layers in other areas.

The upper, comprised at least in part of the sock-like structure, may be attached to a sole. The methods of attachment may include the use of stitches or bonding. In an alternate embodiment, the sole or a portion of the sole or another component of a shoe may also be directly molded onto the sock-like structure. The sole may be constructed as a unitary piece or may be configured to at least have a midsole and an outsole. FIG. 4a-c provides an embodiment of an insole 40 or in the alternate, a midsole, that is molded directly on to the interior surface 28 of the first portion of the sock-like structure. An exemplary material may be polyurethane gel 42, Once the gel is molded on to the sock-like structure, the second portion 8 of the sock-like structure may be folded over the gel and the first portion 6 into the folded configuration as shown in FIGS. 4b -c.

Molded attachments may be any additional component of the upper shoe. It may be added to the interior region between the first portion and second portion. The attachments may be molded directly to the exterior of the upper. Such components may be structural supports or graphics or ornamental features.

FIGS. 5 & 6 show other methods of inserting a component 44 of the sole between the two portions of the sock-like structure. In one embodiment an aperture 46 may be located near the collar region at the axis of the fold of the two portions. The component 44 may be inserted through the aperture 46 which is closed thereafter. In a an alternate embodiment, the component may be inserted through the open toe end or another aperture formed near the bottom of sock-like structure. Once the component of the sole is properly located between the two portions, the sock-like structure and component of the sole may be further secured and conformed by such processes as heating.

Other materials such as terry knit, additional fabrics, gels, and/or pelleted foam may be used to enhance cushioning of the article of footwear. Fluid bladders may also be inserted where the bladders may be filled with air, liquid, and/or gels. More rigid materials may also be included to provide increase stability or spring action. Such rigid materials may be in the form of a shank inserted within the sole in such areas as the midfoot arch region. In the alternate, the rigid material may be configured to provide a cantilever like spring resilience and may extend the full-length of the foot.

FIG. 7 shows an exemplary embodiment in which a midsole 48 is located between the two portions. The midsole may have protruding lugs that extend through apertures 44 created in the second portion. The protruding lugs 50 may be inserted into an outsole or form at least a portion of the outsole bottom. Additional outsole attachments may be affixed over the midsole piece. In an alternative embodiment, a complete outsole may be molded on to the first portion and the second portion may have an aperture large enough to allow the outsole to be exposed. Portions of the second portion may be then secured to a portion of the outsole.

Other structural or ornamental components such as an eyelet, heel counter, toe cap, foxing, mudguard, quarter support, additional vamp cover, overlay, logo, or decorative piece may be attached to the sock-like structure. Structural pieces may be rigid. Such pieces may be formed by carbon fiber or any other materials known in the art. Such pieces may be bonded using hot melt thermoplastic material or adhesives. Alternatively, such pieces may be stitched on to the sock-like structure. An advantage of having components inserted between the two portions of the sock-like structure would be to provide a seamless interior of the upper which provides better comfort and less irritation to the foot. However, such pieces may be located on any of the surfaces of the sock-like structure. FIG. 8 shows one exemplary embodiment of structural supports that are located between the two portions 6 and 8 such as the heel cup 52, midfoot region 54, and toe cap 56.

Robotic three-dimensional conformal printing and dispensing methods of materials may also be applied to any portion of the sock-like structure. Such methods include providing structural support, cushioning, and ornamentation to both the interior and exterior surfaces of the sock-like structure. One such method dispenses a two-component thermoset polyurethane (PU) foam directly on to the interior of the sock-like structure that is placed on the last. The PU foam may be “drawn” on to the sock-like structure by controlling the position and orientation of the last relative to the PU foam dispensing system, A robotic arm may be used to control the positioning of the last. In one preferred embodiment, the robotic arm has six axes of rotation.

Hosiery may be applied to the sock-like structure as well. Hosiery 58 may be constructed by a circular hosiery machine using TPU yarn as shown in FIG. 9. Such hosiery may be applied to both the outer and inner portions of the sock-like structure. Hosiery containing TPU may be partially melted in order to be affixed to the sock-like structure and molded to its proper configuration. External attachments may be incorporated into the layers of the hosiery. The external attachments may be molded directly to one or more of the layers. The external attachments may include portions of the sole, support structures, logos, and/or ornamentation, etc.

The upper may also incorporate a tongue or additional material in the vamp region. The tongue may be integrally knit as part of the sock-like structure or separately formed and then attached to the sock-like structure. The tongue may be separated from the upper on the lateral and medial side of the throat area and attached or integrally knit with the upper at the tongue's forward portion.

The upper may also have eyelets 60 for laces or aesthetics either cut into the sock-like structure or integrally embroidered on to the sock-like structure. FIGS. 10a-c shows one exemplary embodiment. The eyelets may extend through both portions or a single portion of the sock-like structure such as only the second portion. FIGS. 11a-c shows an upper with an integrally knit single wall 62 that extends away from the exterior surface of the second portion of the sock. The single wall may not be entirely secured to the external surface of the second portion. The unsecured part of the wall may be considered as a knitted flap extending from the external surface. The wall may also have eyelets that are either cut out or are integrally knitted to form holes.

In a preferred embodiment, the interior surface of the two portions may have knits or fibers that provide additional cushioning. Such knits may include terry knits or floating yarns. Such cushioning knits 64 may be located at an area that is proximal to the bottom of the foot as shown in FIGS. 12a-c . In this embodiment, both interior surfaces 28 and 32 have these integrally knit cushioning areas, Other embodiments may have integrally knit cushioning on any of the surfaces and on any one or more locations on the upper.

The upper may also have knit pockets or sleeves. The pockets may be located on the outer exterior surface of the sock-dike structure. Such pockets 66 may be used to hold structural reinforcements 68 or keys 70 or other items as shown in FIGS. 3a-c and FIGS. 14a-c . The pockets in the form of sleeves may be located on the bottom of the sock-like structure or any other area, and may be used to secure sockliners insoles or even midsoles.

Regarding FIGS. 15a-d , the exemplary embodiment provides a sock-like structure with two portions not forming a complete collar and heel counter of the upper 2. Rather a collar 72 and a heel counter piece 74 may be attached to the upper 2. In the alternate, the second portion of the sock-like structure may not have the same dimensions as the first portion. In this alternate embodiment, the second portion partially covers the first portion such that the collar portion of the sock-like structure is entirely composed of either the first or second portion.

The collar portion may be folded and stitched to form loops in, the knitted textile. The loops may be separately constructed and attached directly to the sock-like structure. Such loops may be hollowed or filled with filler, cords, or terry knit structures. In one exemplary embodiment, two collar loops 76 may be formed where the loops are integrally knitted to the first portion 6 and second portion 8 and are anchored by stitches as shown in the cross-section diagram of FIG. 16.

Other types of loops may be formed and used to create structural supports or ornamental features. FIG. 17A and FIG. 17B show a loop 78 formed at the toe box 80 which creates a channel 82 in the shape of “U” around the toe box. A cord 84 may be inserted into the channel giving rise to an elevated U-shaped rim. The loop 78 may be secured by stitching, fasteners, adhesives, or hot melt yarn or material.

Although the present invention has been described above by referring to particular embodiments, it should be understood that modifications and variations may be made to these embodiments without departing from the intended scope of invention. 

We claim:
 1. An upper of a shoe comprising: a unitary knitted tubular textile having a first portion, a second portion, and a junction portion, the first portion having a first exterior surface, and a first interior surface; the second portion having a second exterior surface and a second interior surface: the first portion being connected to the second portion at the junction portion; the second portion being folded over the first portion such that the first portion is within the second portion and the junction portion forming part of the periphery of the upper, the first exterior surface forming a surface being the closest portion to a void capable of receiving a foot, the first interior surface being the closest portion to the second interior surface; the second exterior surface arming at least a portion of an exterior surface of the upper; and at least one molded attachment formed by molding the attachment directly on to an area of the unitary knitted tubular textile.
 2. The at least one molded attachment of claim 1 being a portion of the sole of the shoe.
 3. The at least one molded attachment of claim 2 being molded on to a part of the first interior surface.
 4. The molded attachment of claim 1 being molded on to the second portion.
 5. The at least one molded attachment of claim 1 comprising a cushion.
 6. The at least one molded attachment of claim 1 comprising a rigid support.
 7. The upper of claim 1 having at least one elastic region in the knit textile.
 8. The upper of claim 1 further at least one aperture.
 9. The upper of claim 9 wherein a part of the molded attachment extends through the at least one aperture.
 10. The part of the molded attachment of claim 9 comprising at least a part of a sole.
 11. The upper of claim 1 further comprising of a component fixed to an area of the upper between the first portion and the second portion.
 12. The upper of claim 1 further comprising of a component fixed to the area of the upper on the exterior surface.
 13. The component of claim 12 being a separately formed textile that forms at least a portion of a collar of the upper.
 14. The unitary knitted textile of claim 1 further comprising of thermoplastic fusible fibers.
 15. The unitary knitted textile of claim 1 further comprising one or more extensions that form flaps, pockets, slits or eyelets.
 16. The unitary knitted textile of claim 1 further comprising a channel in the toe box of the upper wherein the channel is formed by the second portion and secured by stitching two regions of the second portion.
 17. An upper of a shoe comprising: a unitary knitted tubular textile having a first portion, a second portion, and a junction portion, the first portion having a first exterior surface, and a first interior surface; the second portion having a second exterior surface and a second interior surface; the first portion being connected, to the second portion at the junction portion; the second portion being folded over the first portion such that the first portion is within the second portion and the function portion forming part of the periphery of the upper, the first exterior surface forming a surface being the closest portion to a void capable of receiving a foot, the first interior surface being the closest portion to the second interior surface; the second exterior surface forming at least a portion of an exterior surface of the upper; and a cushion layer formed by molding the cushion layer directly on to an area of the unitary knitted tubular textile, the cushion layer being located in an area that is underneath the void capable of receiving a foot.
 18. A method of forming an upper of a shoe comprising: knitting a tubular textile having a first portion, and a second portion, the first portion having a first exterior surface, and a first interior surface, the second portion having a second exterior surface and a second interior surface, the first portion connected to the second portion; molding an attachment directly on to at least an area of the first interior surface, folding the first portion inwardly into the second portion wherein the first exterior surface forming a surface being the closest portion to a void capable of receiving a foot, and the first interior surface being the closest portion to the second interior surface, and the second exterior surface forming at least a portion of an exterior surface of the upper; and the area of the attachment being at least located between the first interior surface and the second interior surface.
 19. The method of claim 18 wherein at least a part of the attachment is located underneath the void capable of receiving a foot.
 20. The method of claim 18 wherein the attachment comprises part of the sole. 